The DSG Dual-Clutch Gearbox

Environmental Commendation –
Background Report
Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Shift up to environmental protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 The DSG dual-clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Wet or dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Life Cycle Assessments for ecological product evaluation and optimisation. . . . . . . . . . . 7

2.1 Life Cycle Inventory – LCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Life Cycle Impact Assessment – LCIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Implementation at Volkswagen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 The automatic transmissions assessed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Aim and target group of the assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2 Function and functional unit of the vehicle systems assessed . . . . . . . . . . . . . . . . . . .12
3.3 Scope of assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Environmental Impact Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Basis of data and data quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Model assumptions and findings of the Life Cycle Assessment . . . . . . . . . . . . . . . . . . 18

5 Results of the Life Cycle Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.1 Material composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Results of the Life Cycle Inventory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.3 Comparison of Life Cycle Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 Technologies for the future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bibliography and list of sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
List of abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34


Introduction

Introduction
Volkswagen develops environmentally friendly technologies that help reduce CO 2
emissions and makes them available throughout the product range. That way, all our
customers benefit from our development work. Our technologies reduce the carbon
dioxide emissions of the vehicle fleet and play a key role in making vehicles more
environmentally compatible. The DSG dual-clutch gearbox, designed to replace
conventional automatic transmissions with torque converters, is a case in point. DSG
gearboxes are to be available with almost all the petrol and diesel engine options in the
new Golf range and are considerably more efficient than conventional automatic
transmissions. Innovations of this type make our models better and improve their
environmental compatibility in particular.

Volkswagen uses environmental commendations to document the environmental

progress of its vehicles and technologies compared to their predecessors. Our en-
vironmental commendations provide our customers, shareholders and other stake-
holders inside and outside the company with detailed information about how we are
making our products and production processes more environmentally compatible and
what we have achieved in this respect. The DSG dual-clutch gearbox is the first Volks-
wagen technology to receive an environmental commendation. Our first vehicle
environmental commendations, for the Passat and the Golf, were very well received
both by the public and by the media.

The environmental commendations are based on the results of a detailed Life Cycle
Assessment (LCA) in accordance with ISO 14040/44, which has been verified by inde-
pendent experts, in this case from TÜV NORD. Volkswagen already has a long tradition
in this field: we have been analysing our cars and their individual components for more
than ten years, using Life Cycle Assessments to enhance their environmental compati-
bility. As part of an integrated product policy, the LCA considers not only individual
environmental aspects such as the driving emissions of a vehicle, but the entire product
life cycle. This means that all the processes from the production and use of a gearbox
right through to disposal are considered in the analysis, “from cradle to grave”.


Summary

Summary
This environmental commendation compares current Volkswagen DSG dual-
clutch gearboxes (6- and 7-speed) with conventional torque converter automatic
transmissions. We have assessed the emissions caused by the gearbox not only
during use but over its entire life cycle, from production to disposal.

As in the case of the Golf and Passat, the DSG gearboxes show improvements, in
some cases significant, in all the environmental impact categories. The greatest
advances have been made in the areas of global warming potential (greenhouse
effect), acidification and photochemical ozone (summer smog) creation poten-
tial. In other respects, such as water and soil eutrophication and ozone depletion,
the changeover from conventional automatic transmissions to DSG gearboxes
has little impact. It emerged that these improvements were primarily due to
reduced fuel consumption and the resultant drop in driving emissions and
reduction in environmental impact at the fuel production stage. The reduction in
fuel consumption, in turn, is the direct result of the intelligent gearbox manage-
ment and high efficiency of the DSG gearbox.


1 Shift up to environmental protection

Shift up to environmental protection

Volkswagen develops environmentally friendly technologies that help reduce CO2 emis-
sions. Our TDI and TSI engines, millions of which have been produced, are examples of
environmentally compatible innovation. However, the fuel consumption and CO2 emissi-
ons of a vehicle are not only determined by its engine. Volkswagen is committed to
tapping all the opportunities for reducing fuel consumption and making technologies
even more climate-compatible in the future. Our especially frugal BlueMotion models
already meet these targets today. Our Powertrain and Fuel Strategy describes the technolo-
gies being pursued by Volkswagen with a view to implementing a long-term changeover to
sustainable fuels and powertrains. Biofuels are just as much a part of this strategy as the
fuel cell or electric propulsion systems.

Powertrain and Fuel Strategy of the Volkswagen Group

Electricity Electrotraction

Renewable Hydrogen (Regenerative) Fuel Cell

SunFuel® CCS®

Natural Gas SynFuel Hybrid

Oil Diesel Fuel

Gasoline / CNG TDI®/ TSI®/ DSG®

Fig. 1: Powertrain and Fuel Strategy of the Volkswagen Group

The DSG dual-clutch gearbox

The DSG intelligent automatic transmission developed by Volkswagen is also an
integral part of this strategy for the future. In 2002, Volkswagen presented the first dual-
clutch gearbox intended for series production, the 6-speed DSG. The dual-clutch prin-
ciple ensures higher efficiency and lower fuel consumption than a conventional auto-
matic transmission. In addition, it also makes for greater comfort and driving pleasure.
In the meantime, Volkswagen has introduced a second dual-clutch gearbox, the 7-speed
DSG, which is even more economical and will be used in the future on high-volume
models with power outputs up to 125 kW and torque values up to 250 Nm.

Since the DSG dual-clutch gearbox was first launched, more than a million units have
been sold, resulting in a new boom in automatic transmissions at Volkswagen. The pro-
portion of new vehicles equipped with automatic transmissions has risen dramatical-
ly, from 5 to 10 percent with conventional transmissions to as much as 30 percent
with the DSG. With the new 7-speed DSG, even more customers will automatically
shift up to environmental protection.


1 Shift up to environmental protection

Wet or dry
The DSG dual-clutch gearbox developed by Volkswagen combines the comfort and con-
venience of an automatic transmission with the efficiency and performance of a manual
gearbox. Two clutches ensure that shifts take place in next to no time. When a shift is im-
minent, one clutch disengages while the other is engaging, both in a few hundredths of a
second. This is possible because the transmission always preselects the next gear to be
used.

Rapid, precise shifting is the key advantage of the DSG over conventional automatic
transmissions. With a DSG gearbox, there is no perceptible interruption in tractive force
and therefore no jolting during gearshifts. And the dual-clutch gearbox also boasts much
higher efficiency, saving fuel and cutting carbon dioxide emissions. And for those who
still want to change gears manually, the Tiptronic shift function makes this possible too.

Volkswagen offers the 6- and 7-speed DSG gear-boxes for models with various different
engines. While the 6-speed DSG, introduced in 2002, is used for high-torque engines up
to 350 Nm, the 7-speed DSG is available for engines with torque figures up to 250 Nm. The
key innovation on the 7-speed unit is its „dry“ dual clutch. In contrast to the six-speed
DSG, the new transmission does not have a „wet“ clutch with oil cooling. This change
results in a whole raft of benefits, all leading to a further improvement in efficiency.

With the dual clutch, the efficiency of the DSG gearbox is significantly higher than that of
conventional automatic transmissions fitted with hydraulic torque converters. Thanks to
the DSG‘s intelligent transmission control system, its outstanding efficiency and its low-
er weight, vehicles equipped with the 7-speed dual-clutch gearbox may even present
lower fuel consumption than comparable manual vehicles, depending on the individual
style of driving.


2 Life Cycle Assessments for ecological product evaluation and optimisation

Life Cycle Assessments for ecological product

evaluation and optimisation
The environmental goals of the Technical Development department of the Volkswagen
brand state that we develop our vehicles in such a way that, in their entirety, they present
better environmental properties than their predecessors (Fig. 2) By „in their entirety“, we
mean that the entire product life cycle is considered, from cradle to grave.

Fig. 2: Environmental goals of the Technical Development department of the Volkswagen brand


2 Life Cycle Assessments for ecological product evaluation and optimisation

This environmental commendation considers the significance of the innovative DSG

technology for the environmental profile of a transmission. The decisive factor for the
environmental profile of a product is its impact on the environment during its entire
„lifetime“. This means we do not focus solely on a product‘s service life but also on the
phases before and after, i.e. we draw up a balance sheet that includes the manufacturing,
disposal and recycling processes. All life cycle phases require energy and resources, cause
emissions and generate waste. Different vehicles and technologies can only be effectively
compared on the basis of a balance sheet that covers all these individual processes from
„cradle to grave“. And this is precisely what Life Cycle Assessments or LCAs facilitate. Our
Life Cycle Assessments enable the environmental impacts related to a product to be
accurately quantified and thus allow the description of its environmental profile on the
basis of comparable data. To ensure that the results meet exacting quality and comparabi-
lity requirements, when drawing up the Life Cycle Assessments we take our lead from the
standard series ISO 14040 [ISO 2006]. This specifically includes the verification of the
results by an independent expert. In this case, a critical review was conducted by the TÜV
NORD technical inspection agency.

The first stage in preparing a Life Cycle Assessment is to define its objectives and the target
groups it is intended to address. This definition clearly describes the systems to be
evaluated in terms of the system function, the system limits1 and the functional unit2. The
methods of environmental Impact Assessment, the environmental impact categories
considered, the evaluation methods and, if necessary, the allocation procedures3 are
defined in accordance with ISO 14040. The individual steps involved in preparing a Life
Cycle Assessment are described briefly below.

Life Cycle Inventory – LCI

In the Life Cycle Inventory, data is collected for all processes within the scope of the
evaluation. Information on inputs, such as raw materials and sources of energy, and
outputs, such as emissions and waste, is compiled for each process, always with
reference to the defined scope of the evaluation (see Fig. 3).

Manufacturing Production
Energy Emissions
& &
Resources Waste

Recycling Utilisation

Fig 3: Input and output flows for a Life Cycle Inventory

1 By defining the system limits, the scope of the Life Cycle Assessment is restricted to those processes and material .
flows that need to be evaluated in order to achieve the defined goal of the study.
2 The functional unit quantifies the benefit of the vehicle systems evaluated and further ensures their comparability.

3 Where processes have several inputs and outputs, an allocation procedure is needed to assign flows arising from .

the product system under evaluation to the various inputs and outputs.


2 Life Cycle Assessments for ecological product evaluation and optimisation

The Life Cycle Inventory of an entire product life cycle includes numerous different inputs
and outputs that are ultimately added up to prepare the inventory.

Life Cycle Impact Assessment – LCIA

A Life Cycle Inventory only quantifies the inputs and outputs of the system investigated.
The following step – Impact Assessment – allocates the respective material flows to the
appropriate environmental impacts. This involves defining a reference substance for
each environmental impact category, for instance carbon dioxide (CO 2) for the impact
category „global warming potential“. Then all substances that also contribute to the
global warming potential are converted to CO2 equivalents using equivalence factors4.

Product Life Cycle

Manufacturing Production Utilisation Recycling

fuel and materials

CO2 CH4 NOX ... CO2 VOC ... CO2 VOC NOX ... CO2 SO2 NOX ...

Life Cycle Inventory

NCH4 NVOC NCO2 NNOX N...

Impact Assessment
Global warming Photochemical Acidification Eutrophication ...
ozone creation

Normalisation
of environmental impacts with average impact per inhabitant:
How many inhabitants cause the same environmental impact as the product evaluated?

Fig. 4: Procedure for Impact Assessment

Examples of environmental categories are global warming potential, photochemical

ozone creation potential, acidification potential or eutrophication potential.

Evaluation
The subsequent final evaluation interprets and evaluates the results of the Life Cycle
Inventory and the Life Cycle Impact Assessment. The evaluation is based on the defined
goal and scope of the Life Cycle Assessment.

4 Carbon dioxide (CO2) is the reference substance for global warming potential. All substances that contribute
to the greenhouse effect are converted into CO 2 equivalents through an equivalence factor. For instance, the
global warming potential of methane (CH4) is 23 times higher than for CO2. In concrete terms this means that the
emission of 1 kg of CO2 and 1 kg of CH4 leads to a net global warming potential of 24 kg CO2 equivalents. All the
emissions that contribute to the greenhouse effect are measured in this way.


2 Life Cycle Assessments for ecological product evaluation and optimisation

Implementation at Volkswagen
Volkswagen has many years of experience with Life Cycle Assessments for product and
process optimisation. We have even assumed a leading role in implementing and
publishing life cycle inventories of complete vehicles. For instance, in 1996 we were the
first car manufacturer in the world to prepare a Life Cycle Inventory study (for the Golf
III) and publish it [Schweimer and Schuckert 1996]. Since then we have drawn up Life
Cycle Assessments for other cars and also published some of the results [Schweimer
1998; Schweimer et al. 1999; Schweimer and Levin 2000; Schweimer and Roßberg 2001].
These LCAs primarily describe and identify environmental „hot spots“ in the life cycle
of a car. Since then we have broadened the assessments to include production pro-
cesses as well as fuel production and recycling processes [Bossdorf-Zimmer et al. 2005;
Krinke et al. 2005b]. Since 2007, we have used environmental commendations to inform
customers about the environmental properties of our vehicles [Volkswagen AG 2007a,
2007b, 2008]. Volkswagen is making long-term investments in further developing and
optimising Life Cycle Assessment methods. Thanks to our intensive research we have
succeeded in considerably reducing the workload involved in preparing Life Cycle In-
ventories.

Our research resulted in the development of the VW slimLCI interface system [Koffler et
al. 2007]: this interface not only significantly cuts the workload involved in preparing
Life Cycle Assessments of complete vehicles by automating the process, but also further
improves the consistency and quality of the LCA models produced. This represents
substantial progress, since preparing a complete LCA for a vehicle involves registering
thousands of components, together with any related upstream supply chains and pro-
cesses (see Fig. 5).

Fig. 5: Dismantling study of the Golf V

10
2 Life Cycle Assessments for ecological product evaluation and optimisation

The complexity of the modelling process results from the fact that all the parts and
components of a vehicle themselves consist of a variety of materials and are manufactured
by many different processes – processes that in turn consume energy, consumables and
fabricated materials. In addition, the correct assignment of manufacturing processes to
materials calls for considerable expert knowledge, a large database and detailed informa-
tion on production and processing steps. The VW slimLCI interface system allows these
details to be modelled very precisely and sufficiently completely in Life Cycle Assessment
models – even for entire vehicles. A Life Cycle Assessment or product model is based on
the vehicle parts lists drawn up by the Technical Development department, as well as on
material data drawn from the Volkswagen AG Material Information System (MISS). The
VW slimLCI interface system primarily consists of two interfaces that transfer the vehicle
data from these systems to the Life Cycle Assessment software GaBi 5, using a defined
operating sequence (algorithm) (see Fig. 6).

slimLCI

Product
MISS GaBi software
parts list

Material data Interface 1 Transfer file Interface 2 Product model

Manual
consolidation

Database Electronic data

Predefined process Manual processing

Fig. 6: Process of modelling an entire vehicle with the VW slimLCI interface system

Interface 1 helps assign information from parts lists (part designations and quantities) to the
relevant component information (materials and weights) from MISS and converts it into a
transfer file which is then quality-tested (manual consolidation). Interface 2 then allows the
transfer file to be linked with the related data sets in the GaBi Life Cycle Assessment soft-
ware. For example, to each material, such as steel sheet, the interface allocates all the
material production and subsequent treatment processes listed in the database. The model
generated by GaBi therefore reflects all the processing stages in the manufacture of the
entire vehicle being evaluated. So with the VW slimLCI interface system we can prepare Life
Cycle Assessments in a very short time and use them continuously in order to keep pace
with the steadily growing demand for environment-related product information.

5 GaBi® is a Life Cycle Assessment software package from PE international.

11
3 The automatic transmissions assessed

The automatic transmissions assessed

This environmental commendation for the DSG dual-clutch gearbox describes and
analyses the environmental impacts of various automatic transmissions. To this end we
have compared the current 6-speed and 7-speed DSG units with conventional automa-
tic transmissions equipped with torque converters. The results are based on Life Cycle
Assessments drawn up in accordance with the standards DIN EN ISO 14040 and 14044.
All the definitions and descriptions required for preparing these Life Cycle Assessments
were drawn up in accordance with the standards mentioned above and are explained
below.

Aim and target group of the assessment

Volkswagen has been producing Life Cycle
Assessments for over ten years to provide
detailed information on the environmen-
tal impacts of vehicles and components
for our customers, shareholders and other
interested parties within and outside the
company.

The objective of the Life Cycle Assessment

in this case was to compare the environ-
mental profiles of various types of auto-
matic transmission. To this end we compa-
red the current 6-speed and 7-speed DSG
dual-clutch gearboxes with a conven-
tional torque converter transmission.

Function and functional unit of the vehicle systems assessed

The “functional unit” for the assessment was defined as the transmission of torque in a
powertrain over a total distance of 150,000 kilometres in the New European Driving Cycle
(NEDC). However, within the Volkswagen Group, no vehicle is or has been offered with all
three transmissions considered. In order to ensure comparability, it was therefore necessary
to base the assessment of the service life phase on fuel consumption simulations. For this
purpose, the transmissions were „virtually installed“ on the same reference vehicle, a Golf
1.4 TSI with 90 kW 6, and the resulting consumption figures for the entire vehicle were
determined on the basis of otherwise unchanged assumptions.

With the exception of the Golf 1.4 TSI with 7-speed DSG, the consumption figures stated
are therefore calculated, rather than measured, values7. In line with the functional unit
defined above, in what follows we only indicate the resulting consumption benefits com-
pared with the torque converter transmission. This differential approach has also been
applied to the production and recycling phases. The key technical data of the transmissions
compared are listed in Table 1.

6 5.9
l/100 km (NEDC), 139 g CO2/km
7 Thedeviation determined in the simulation for the Golf 1.4 TSI with 90 kW and 7-speed DSG (5.9 l/100km, .
139 g CO2/km) was 1.7 %. The simulation is therefore considered to be sufficiently accurate.

12
 3 The automatic transmissions assessed

Table 1: Technical data of transmissions compared

Torque converter 6-speed DSG ® 7-speed DSG ®

transmission

Number of gears 6 6 7

Max. torque 320 Nm 350 Nm 250 Nm

Clutch - Wet Dry

Gear oil volume 5.8 l 6.5 l 1.7 l

Weight a 85 kg 93 kg 77 kg

Consumption advantageb Reference -0.3 l/100 km -0.8 l/100 km

Efficiencyc 83 % 85 % 91 %

a
including double-mass flywheel and oil
b compared with a Golf V 1.4 TSI 90 kW with torque converter transmission (model calculation)
c average efficiency in 5 th gear

Scope of assessment
The scope of the assessment was defined in such a way that all relevant processes and
substances are considered, traced back to the furthest possible extent and modelled at
the level of elementary f lows in accordance with ISO 14040. This means that only
substances and energy flows taken directly from the environment or released into the
environment without prior or subsequent treatment exceed the scope of the assessment.
The only exceptions to this rule are the material fractions formed in the recycling stage.

The transmission manufacturing phase was modelled including all manufacturing and
processing stages for all components used. The model included all steps from the
extraction of raw materials and the manufacture of semifinished products right through
to assembly.

As regards the service life of the transmission, the model includes all relevant processes
from fuel production and delivery through to actual driving. The analysis of the fuel
supply process includes shipment from the oilfield to the refinery and the refining
process. Vehicle maintenance is not included in the assessment as previous studies
demonstrated that maintenance does not cause any significant environmental impacts
[Schweimer and Levin, 2000].

The model of the recycling phase includes the dismantling and shredding of the trans-
mission as well as the recycling of material fractions by appropriate processes. In this
Life Cycle Assessment, no environmental credits were awarded for the secondary raw
material obtained from the recycling process. We only included the environmental
impacts of the recycling processes required. This corresponds to a worst case assumption8,

13
3 The automatic transmissions assessed

since in reality secondary raw material from vehicle recycling is generally returned to the
production cycle. This recycling and substitution of primary raw materials avoids the
environmental impact of primary raw material production.

As a general principle, only emissions and fuel consumption actually caused by the
transmission are taken into consideration in the Life Cycle Assessment. In order to assess
the change in fuel consumption caused by the use of a specific transmission, it was
necessary in some cases to use simulated NEDC consumption figures as no vehicle with
measured consumption figures for all three transmission variants was available. This
differential or consumption advantage approach was also applied to the production and
recycling phases. The results of this analysis show the increase or reduction in potential
environmental impacts that would be caused by a changeover from a torque converter
transmission to a DSG dual-clutch gearbox on the same vehicle (Golf 1.4 TSI 90 kW)9.

Fig. 7 is a schematic diagram indicating the scope of the Life Cycle Assessment. Europe
(EU 15) was chosen as the reference area for all processes in the manufacture, service
and recycling phases.

Scope of assessment

Production of raw material

Production → pipeline

Production of materials Transport → refining

Recovery of energy
Production of components Fuel supply and raw materials

Manufacturing Service life Recycling

Maintenance Credits

Fig. 7: Scope of the Life Cycle Assessment

8 Here the worst case is a set of most unfavourable model parameters of the recycling phase.
9 5,9 l/100 km (NEFZ), 139 g CO 2/km

14
3 The automatic transmissions assessed

Environmental Impact Assessment

The Impact Assessment is based on a method developed by the University of Leiden in
the Netherlands (CML methodology) [Guinée and Lindeijer 2002]. The assessment of
environmental impact potentials in accordance with this method is based on recognised
scientific models. A total of five environmental impact categories10 were identified as
relevant and were then assessed in this study:

• eutrophication potential
• ozone depletion potential
• photochemical ozone creation potential
• global warming potential for a reference period of 100 years
• acidification potential

The above environmental impact categories were chosen because they are particularly
important for the automotive sector, and are also regularly used in other automotive-
related Life Cycle Assessments [Schmidt et al. 2004; Krinke et al. 2005a]. The environ-
mental impacts determined in the Life Cycle Assessments are measured in different
units. For instance, the global warming potential is measured in CO2 equivalents and
the acidification potential in SO 2 equivalents (each in kilograms). In order to make
them comparable, a normalisation process is necessary. In this Life Cycle Assessment
the results were normalised with reference to the annual average environmental impact
caused by an inhabitant of the EU15. For example, in the global warming category, each
inhabitant of the European Union caused the emission of about 12.6 metric tons of CO2
equivalents in the year 2001.

Table 2: Average impact per inhabitant figures in the EU 15,

referred to an inhabitant in 2001 [PE International 2003]

Environmental category Per capita Unit

Eutrophication potential 33.22

kg PO4 equivalents

Ozone depletion potential 0.22

kg R11 equivalents

Photochemical ozone creation potential 21.95

kg ethene equivalents

Global warming potential 12,591.88

kg CO2 equivalents

Acidification potential 72.85

kg SO2 equivalents

This normalisation allows statements to be made regarding the contribution of a

product to total environmental impacts within the European Union. The results can
then be presented in one graph using the same scale. This approach also makes the
results more comprehensible and allows environmental impacts to be compared.
In Table 2, we have listed the average figures per inhabitant for the individual impact
categories. In this context it must be pointed out that the normalisation does not give

10 The glossary contains a detailed description of these environmental impact categories.

15
3 The automatic transmissions assessed

any indication of the relevance of a particular environmental impact, i.e. it does not
imply any judgement on the significance of individual environmental impacts.

Basis of data and data quality

The data used for preparing the Life Cycle Assessment can be subdivided into product
data and process data. “Product data” describes the product itself, and among other
things includes:

• Information on parts, quantities, weights and materials

• Information on fuel consumption and emissions during utilisation
• Information on recycling volumes and processes.

“Process data” includes information on manufacturing and processing steps such as the
provision of electricity, the production of materials and semifinished goods, fabrication
and the production of fuel and consumables. This information is either obtained from
commercial databases or compiled by Volkswagen as required.

We ensure that the data selected are as representative as possible. This means that the
data represent the materials, production and other processes as accurately as possible
from a technological, temporal and geographical point of view. For the most part, pub-
lished industrial data are used. In addition, we use data that are as up-to-date as
possible and relate to Europe. Where European data are not available, German data are
used. For the various transmissions we always use the same data on upstream supply
chains for energy sources and materials. This means that differences between the latest
models and their predecessors are entirely due to changes in component weights, ma-
terial compositions, manufacturing processes at Volkswagen and driving emissions,
and not to changes in the raw material, energy and component supply chains.

The Life Cycle Assessment model for transmission production was developed using
Volkswagen‘s slimLCI methodology (see Chapter 1). Transmission parts lists were used
as data sources for product data, and the weight and materials of each product were
taken from the Volkswagen material information system (MISS). This information was
then linked to the corresponding process data in the Life Cycle Assessment software
GaBi.

Material inputs, processing procedures and the selection of data in GaBi are standar-
dised to the greatest possible extent, ensuring that the information provided by VW
slimLCI is consistent and transparent.

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3 The automatic transmissions assessed

For the modelling of the vehicle’s service life, representative data for upstream fuel
supply chains were taken from the GaBi database. A sulphur content of 10 ppm was
assumed for petrol 11.

Transmission recycling was modelled on the basis of data from the VW SiCon process
and using representative data from the GaBi database.

In sum, all information relevant to the aims of this study was collected and modelled
completely12. The modelling of components on the basis of vehicle parts lists ensures
that the model is complete, especially with respect to the manufacturing phase. In
addition, as the work processes required are automated to a great extent, any diffe-
rences in the results are due solely to changes in product data and not to deviations in
the modelling system.

11 Insome countries, fuel with a sulphur content of 10 ppm is not yet available. However, even if the sulphur
content were higher, the contribution of sulphur emissions during the vehicle’s service life would still remain
negligible.
12 Completeness, as defined by ISO 14040, must always be considered with reference to the objective of the

investigation. In this case, completeness means that the main materials and processes have been reflected. Any
remaining data gaps are unavoidable, but apply equally to all the transmissions compared.

17
4 Model assumptions and findings of the Life Cycle Assessment

Model assumptions and findings of the Life

Cycle Assessment
All the framework conditions and assumptions defined for the Life Cycle Assessment
are outlined below.

Table 5: Assumptions and definitions for the Life Cycle Assessment

Aim of the Life Cycle Assessment

• Comparison of the environmental profiles of torque converter transmission and

dual-clutch gearbox over the entire life cycle

Scope of assessment

Function of systems
• Transmission of torque in the powertrain

Functional unit
• Transmission of torque in the powertrain in the New European Driving Cycle
(NEDC) over a defined total distance of 150,000 kilometres

Comparability
• Modelling of consumption differences assuming identical framework conditions
/ the same reference vehicle (Golf 1.4 TSI 90 kW13)

System boundaries
• The system boundaries include the entire life cycle of the transmissions
(manufacture, service life and recycling phase).

Cut-off criteria
• The assessment does not include transmission maintenance.
• No environmental impact credits are awarded for secondary raw materials
produced.
• Cut-off criteria applied in GaBi data sets, as described in the software
documentation (www.gabi-software.com)
• Explicit cut-off criteria, such as weight or relevance limits, are not applied.

Allocation
• Allocations used in GaBi data sets, as described in the software documentation
(www.gabi-software.com)
• No further allocations are used

13 5.9 l/100 km (NEDC), 139 g CO2/km

18
4 Model assumptions and findings of the Life Cycle Assessment

Data basis

• Volkswagen transmission parts lists

• Material and weight information from the Volkswagen Material Information
System (MISS)
• Reports of mileage calculations for computation of consumption
• Technical drawings
• The data used comes from the GaBi database or was collected in cooperation
with VW plants, suppliers or industrial partners.

Life Cycle Inventory results

• Material compositions in accordance with VDA (German Association of the
Automotive Industry) Standard 231-106
• Life Cycle Inventory results include emissions of CO2, CO, SO2, NOX, NMVOC,
CH4, as well as consumption of energy resources
• The Impact Assessment includes the environmental impact categories eutrophi-
cation potential, ozone depletion potential, photochemical ozone creation
potential, global warming potential for a reference period of 100 years and
acidification potential
• Standardisation of the results to average impact per inhabitant values

Software

• Life Cycle Assessment software GaBi, GaBi DfX Tool and VW slimLCI interface

Evaluation
• Evaluation of Life Cycle Inventory and Impact Assessment results, subdivided
into life cycle phases and individual processes
• Comparisons of Impact Assessment results of the transmissions compared
• Interpretation of results

19
 5 Results of the Life Cycle Assessment

Results of the Life Cycle Assessment

Material composition
Fig. 8 shows the material compositions derived from the product data on the basis of
VDA (German Association of the Automotive Industry) standard 231-106 for material
classification [VDA 1997]. The bar chart shows that all three transmissions have a similar
composition. The transmissions consist mainly of steel (shafts, gears, etc.) and alu-
minium (cast housing), as well as small amounts of plastics and non-ferrous metals
and the first fill of transmission oil. The differences are mainly due to changes in
overall weights and oil volumes (see Table 1) and the more complex actuation systems
of DSG gearboxes.

100%
Other materials
Fuels and auxiliary means
90%
Polymer materials

80% Non-ferrous metals

Light alloys
70% Steel and iron materials

60%

50%

40%

30%

20%

10%

0%
Torque converter 6-speed DSG 7-speed DSG

Fig. 8: Material composition of transmissions compared

20
 5 Results of the Life Cycle Assessment

Results of the Life Cycle Inventory

Table 4 shows the results for selected life cycle inventory values of the differential
approach adapted. The figures with a light grey background indicate the differences
between the relevant DSG dual-clutch gearbox and a torque converter automatic
transmission.

The figures clearly indicate that the environmental impacts caused by the production
of the two DSG gearboxes are comparable to or slightly higher than the corresponding
figures for a torque converter transmission. In the case of the 6-speed DSG unit, this is
largely due to the total weight of the gearbox, which is the heaviest of the three com-
pared. In the case of the 7-speed DSG, it is mainly the higher mass of non-ferrous metals
and polymers that outweighs the advantage of lower total weight in terms of environ-
mental impact.

As expected, the lower fuel consumption in the service phase leads to a net reduction
in all emissions. As it has been assumed that the same exhaust emission standards
applied to all variants, only the stoichiometric emissions CO2 und SO2 show a reduction
compared with the torque converter transmission.

Table 4: Selected Life Cycle Inventory values (in kg)

CO 2 CO SO 2 NOX NMVOC CH4 Primary

energy

Manufacturing Torque converter 230.5 1.5 0.7 0.4 0.05 0.3 4.0
6-speed DSG (diff.) +53.9 +0.4 +0.1 +0.1 +0.0 +0.1 +0.8
7-speed DSG (diff.) +5.2 +0.0 +0.0 +0.0 +0.0 +0.1 +0.0

Fuel production Torque converter --- --- --- --- --- --- ---
6-speed DSG (diff.) -200.7 -0.2 -1.0 -0.4 -0.5 -1.2 -17.5
7-speed DSG (diff.) -535.1 -0.6 -2.6 -1.1 -1.2 -3.3 -16.5

Driving emissions Torque converter --- --- --- --- --- --- ---
(stoichiometric) 6-speed DSG (diff.) -1,085.0 0.0 -0.1 0.0 0.0 0.0 0.0
7-speed DSG (diff.) -2,892.0 0.0 -0.1 0.0 0.0 0.0 0.0

Recycling Torque converter 93.7 0.3 0.2 0.1 0.01 0.1 1.4
6-speed DSG (diff.) -1.6 0.0 0.0 0.0 0.0 +0.1 +0.1
7-speed DSG (diff.) -20.8 0.0 0.0 0.0 0.0 0.0 -0.1

21
 5 Results of the Life Cycle Assessment

Comparison of Life Cycle Impacts

On the basis of the Life Cycle Inventory data, Life Cycle Impact Assessments are drawn
up for all the environmental impact categories. The interactions of all the emissions
recorded are considered and potential environmental impacts are determined based
on scientific models (see Fig. 4).

In Fig. 9, the base line represents the emissions of the torque converter transmission.
It can clearly be seen that the greatest improvements in environmental impact in
relation to the average per capita environmental impact of inhabitants of Europe (EU15)
are achieved in the categories of global warming potential, acidification and photoche-
mical ozone creation potential. In contrast, the changeover from torque converter
transmissions to the DSG gearbox does not result in any significant improvement in the
categories of ozone depletion and eutrophication.

CO2 equivalents Ethen equivalents SO2 equivalents R11 equivalents PO4 equivalents
[ t ] [ kg] [ kg] [ kg] [ kg]
Average value per inhabitant, EU 15, 2001

0.05

0.00
0.0 -0.2
-0.2
-0.5 -1.0
-0.05
-3.5

-0.10
-1.3

-0.15

-0.20

-0.25

-3.5
-0.30
6-speed DSG

6-speed DSG

6-speed DSG

6-speed DSG

6-speed DSG
7-speed DSG

7-speed DSG

7-speed DSG

7-speed DSG

7-speed DSG

Global warming Photochemical Acidification Ozone depletion Eutrophication

ozone creation

Fig. 9: Life Cycle Impacts (differential) of DSG gearboxes

22
 5 Results of the Life Cycle Assessment

A more precise analysis of the results shows that the improvements in the environmen-
tal profile are chiefly due to the reduction in fuel consumption (Fig. 10). In contrast, the
increases and reductions in impacts caused by production and recycling are relatively
slight and do not have any significant impact on the overall result.

Recycling
Average value per inhabitant, EU 15, 2001

0.05
Driving emissions
Fuel supply
0.00
Production

-0.05

-0.10

-0.15

-0.20

-0.25

-0.30
6-speed DSG

6-speed DSG

6-speed DSG

6-speed DSG

6-speed DSG
7-speed DSG

7-speed DSG

7-speed DSG

7-speed DSG

Global warming Photochemical Acidification Ozone depletion Eutrophication 7-speed DSG

ozone creation

Fig. 10: Life Cycle Impacts (differential) of DSG gearboxes (detail)

23
6 Technologies for the future

Technologies for the future

The Volkswagen Powertrain
and Fuel Strategy covers the
entire range of present and
future drive systems from
current petrol and diesel
engines via hybrid drives and
engines with the Combined
Combustion System (CCS) to
electric vehicles with batteries
or hydrogen technology. In
developing our technologies,
we are committed to reducing
current emission levels and
to ensuring zero-emission
driving to the greatest extent
possible in the future.

As regards fuels, Volkswagen

is engaged in a number of pro-
jects with partners to produce
fuels from various different
raw materials. For Volkswa-
gen, the main emphasis is on
second-generation biofuels
which can be produced from various types of biomass; during combustion, these fuels
only release into the atmosphere the same volume of carbon dioxide as was absorbed
by the plants as they grew. One example is SunFuel, a registered trademark of Volkswa-
gen. SunFuel can be produced from forest or industrial wood residues, animal waste or
straw and therefore does not compete with food production. SunFuel is already being
produced in the world‘s first production plant at Freiberg in Germany. In technical
terms, both petrol and diesel could already be replaced by SunFuel.

The benefits of hybrid drive are particularly evident in urban driving in large cities
or conurbations. Of the various prototypes already presented, the Golf “TwinDrive”
is especially promising. The special feature of the TwinDrive is that the internal combu-
stion engine provides assistance for the electric motor, and not vice versa. This means
that the vehicle can be driven considerable distances without producing any direct
emissions. In electric propulsion mode, the range of the TwinDrive is about 50 kilome-
tres. From 2010, up to 20 vehicles will be involved in an electric mobility fleet test to test
electric propulsion in everyday use

24
6 Technologies for the future

The fuel cell is another technology that demonstrates the innovative capabilities of
Volkswagen. The research and development team at Volkswagen has developed a unique
type of high-temperature fuel cell that eliminates many of the problems associated with
previous low-temperature systems. The high-temperature fuel cell will make the entire
drive system installed in a vehicle lighter, smaller, more durable and less expensive
– and these are the key factors as fuel cells are developed to readiness for industrial scale
production. Volkswagen is expecting to test the first prototypes with high-temperature
fuel cells in 2010. Current forecasts predict that the first production vehicles will not be
launched before 2020.

In the long term, Volkswagen regards the electric motor as the drive system of the future.
A key element in the growing trend towards electrification will be the use of energy from
renewable sources such as wind or solar energy or hydropower. Ideally, an electric
vehicle should be able to „fill up“ directly with electricity. The „tank“ or energy storage
device is a rechargeable battery. This drive configuration has the benefit of high
overall efficiency as the electric power is used directly for propulsion. In contrast to
internal combustion engines, drive systems of this type generate no local emissions.
In a zero-emission study of the space up! blue, Volkswagen has already demonstrated
an electric motor drawing its power from a lithium ion battery system. Powered solely
by batteries, the space up! blue can already cover the average daily distances driven in
today‘s urban traffic.

25
7 Conclusion

Conclusion
The Volkswagen DSG dual-clutch gearbox not only meets the highest comfort and
performance requirements but also, as part of our Powertrain and Fuel Strategy,
represents a key step towards sustainable mobility. This environmental commen-
dation documents the progress that has been achieved in this area compared with a
conventional torque converter automatic transmission. The information provided in
this document is based on the Life Cycle Assessment of the DSG dual-clutch gearbox,
which has been verified and certified by TÜV NORD. The TÜV report confirms that
the Life Cycle Assessment is based on reliable data and was drawn up using a method
in accordance with the requirements of ISO standards 14040 and 14044.

The DSG dual-clutch gearboxes allow lower fuel consumption and emissions than a
conventional torque converter automatic transmission during their service life and
comparable environmental impacts during the manufacturing and recycling phases.
Consequently, in sum, the Life Cycle Assessments of the DSG gearboxes are consi-
derably better than that of a conventional automatic transmission.

26
7 Validation

Validation
The statements made in this environmental commendation are supported by the Life
Cycle Assessment of the DSG dual-clutch transmission. The certificate of validity
confirms that the Life Cycle Assessment is based on reliable data and that the method
used to compile it complies with the requirements of ISO standards 14040 and 14044.

You will find the detailed report from TÜV NORD in the Appendix.

27
Glossary

Glossary
Allocation
Allocation of Life Cycle Inventory parameters to
the actual source in the case of processes that
have several inputs and outputs.
Überschrift für Kreisdiagramm
Average impact per inhabitant figure (EDW) Headline for pie chart

Unit indicating the normalised environmental

impact for a geographical reference area.
Air pollutants
Luftschadstoffe

Eutrophication potential NO
NOXX NH
NH33

describes excessive input of nutrients into water

[or soil], which can lead to an undesirable
change in the composition of flora and fauna.
A secondary effect of the over-fertilisation of
water is oxygen consumption and therefore Düngung
Fertiliser application
oxygen deficiency. The reference substance for
eutrophication is phosphate (PO 4), and all
other substances that impact on this process
(for instance NOX , NH3) are measured in PO
PO44 NO
NO33 NH
NH44

phosphate equivalents. Überschrift für Kreisdiagramm Wastewater

Abwasser
Headline for pie chart
Ozone depletion potential
describes the ability of trace gases to rise into
UVUV-Strahlung
radiation
the stratosphere and deplete ozone there in a
catalytic process. Halogenated hydrocarbons
in particular are involved in this depletion .
process, which diminishes or destroys the
protective function of the natural ozone layer. Stratosphere
Stratosphäre
Absorption
1515– –50
50km
km Absorption
The ozone layer provides protection against
excessive UV radiation and therefore against
genetic damage or impairment of photosynthe- FCKW N2O
sis in plants. The reference substance for ozone
depletion potential is R11, and all other sub-
stances that impact on this process (for instance
CFC, N2O) are measured in R11 equivalents.

28
Glossar

Überschrift für Kreisdiagramm

Photochemical ozone creation potential Headline for pie chart
describes the formation of photooxidants, such
as ozone, PAN, etc., which can be formed.
Hydrocarbons
Kohlenwasserstoffe
from hydrocarbons, carbon monoxide (CO)
Weather
Klima
and nitrogen oxides (NOX), in conjunction with Nitrogen oxides
Stickoxide trocken
dry andund warm
warm
sunlight. Photooxidants can impair human
health and the functioning of ecosystems
and damage plants. The reference substance
for the formation of photochemical ozone is
ethene, and all other substances that impact
OZON
on this process (for instance VOC, NOX and
CO) are measured in ethene equivalents.

Hydrocarbons
Kohlenwasserstoffe

Überschrift für Kreisdiagramm Nitrogen oxides

Stickoxide
Global warming potential Headline for pie chart
describes the emissions of greenhouse gases,
which increase the absorption of heat from solar
radiation in the atmosphere and therefore
increase the average global temperature. The
reference substance for global warming
potential is CO2, and all other substances that Absorption
Absorption
impact on this process (for instance CH4, N2O,
SF6 and VOC) are measured in carbon dioxide
equivalents. Reflection
Reflektion

Infrarot-
Infrared CO2 FCKW CH4
Acidification potential UV radiation
UV-Strahlung
strahlung
Radiation
describes the emission of acidifying sub-
stances such as SO2 and NOX, etc., which
have diverse impacts on soil, water, ecosy-
Überschrift für Kreisdiagramm
stems, biological organisms and material (e.g. Headline for pie chart
buildings). Forest dieback and fish mortality in
lakes are examples of such negative effects.
The reference substance for acidification
potential is SO2, and all other substances that
impact on this process (for instance NOX and
NH3) are measured in sulphur dioxide
equivalents.

Environmental impact category H2SO4 HNO3 SO2 NOX

An environmental indicator that describes an

environmental problem (e.g. the formation of
photochemical ozone)

29
Bibliography and list of sources

Bibliography and list of sources

[Bossdorf-Zimmer et al. 2005] Bossdorf-Zimmer, B.; Rosenau-Tornow, D.; Krinke, S.: Successful Life Cycle
Management: Assessment of Automotive Coating Technologies. Presentation at Challenges for Industrial
Production 2005. Karlsruhe: Institut für Industriebetriebslehre und Industrielle Produktion der TU Karlsruhe.

[Guinée und Lindeijer 2002] Guinée, J. B.; Lindeijer, E.: Handbook on Life Cycle Assessment: Operational
guide to the ISO standards. Dordrecht [et al.]: Kluwer Academic Publishers.

[ISO 2006] International Organization for Standardization: ISO 14040: Environmental Management – Life
Cycle Assessment – Principles and Framework. 2nd ed. Geneva: International Organization for
Standardization.

[Koffler et al. 2007] Koffler, C.; Krinke, S.; Schebek, L.; Buchgeister, J.: Volkswagen slimLCI – a procedure for
streamlined inventory modelling within Life Cycle Assessment (LCA) of vehicles. In: International Journal of
Vehicle Design (Special Issue on Sustainable Mobility, Vehicle Design and Development). Olney:
Inderscience Publishers (in press).

[Krinke et al. 2005a] Krinke, S.; Bossdorf-Zimmer, B.; Goldmann, D.: Ökobilanz Altfahrzeugrecycling –
Vergleich des VW-SiCon-Verfahrens und der Demontage von Kunststoffbauteilen mit nachfolgender
werkstofflicher Verwertung. Wolfsburg: Volkswagen AG. On the internet at www.volkswagen-umwelt.de.

[Krinke et al. 2005b] Krinke, S.; Nannen, H.; Degen, W.; Hoffmann, R.; Rudloff, M.; Baitz, M.: SunDiesel – a
new promising biofuel for sustainable mobility. Presentation at the 2nd Life-Cycle Management Conference
Barcelona. On the Internet at www.etseq.urv.es/aga/lcm2005/99_pdf/Documentos/AE12-2.pdf.

[PE International 2003] PE International GmbH: GaBi 4.2 Datenbank-Dokumentation. Leinfelden-

Echterdingen: PE International GmbH.

[Schmidt et al. 2004] Schmidt, W. P.; Dahlquist, E.; Finkbeiner, M.; Krinke, S.; Lazzari, S.; Oschmann, D.;
Pichon, S.; Thiel, C.: Life Cycle Assessent of Lightweight and End-Of-Life Scenarios for Generic Compact
Class Vehicles. In: International Journal of Life Cycle Assessment (6), S. 405-416.

[Schweimer 1998] Schweimer, G. W.: Sachbilanz des 3-Liter-Lupo. Wolfsburg: Volkswagen AG.

[Schweimer et al. 1999] Schweimer, G. W.; Bambl, T.; Wolfram, H.: Sachbilanz des SEAT Ibiza. Wolfsburg:
Volkswagen AG.

[Schweimer und Levin 2000] Schweimer, G. W.; Levin, M.: Sachbilanz des Golf A4. Wolfsburg: Volkswagen AG.

[Schweimer und Roßberg 2001] Schweimer, G. W.; Roßberg, A.: Sachbilanz des SEAT Leon. Wolfsburg:
Volkswagen AG.

[Schweimer und Schuckert 1996] Schweimer, G. W.; Schuckert, M.: Sachbilanz eines Golf. VDI-Bericht 1307:
Ganzheitliche Betrachtungen im Automobilbau. Wolfsburg: Verein Deutscher Ingenieure (VDI).

30
Bibliography and list of sources

[VDA 1997] Verband der deutschen Automobilindustrie (VDA): VDA 231-106: VDA-Werkstoffblatt:
Werkstoffklassifizierung im Kraftfahrzeugbau – Aufbau und Nomenklatur. Frankfurt: Verband der
Automobilindustrie e.V.

[Volkswagen AG 2007a] Volkswagen AG: The Passat – Environmental Commendation, Wolfsburg:

Volkswagen AG. On the Internet at www.umweltpraedikat.de

[Volkswagen AG 2007b] Volkswagen AG: The Golf - Environmental Commendation, Wolfsburg:

Volkswagen AG. On the Internet at www.umweltpraedikat.de

[Volkswagen AG 2008] Volkswagen AG: The Golf - Environmental Commendation, Wolfsburg:

Volkswagen AG. On the Internet at www.umweltpraedikat.de

31
List of abbreviations

List of abbreviations
AP Acidification potential
CFC Chlorfluorocarbons
CH4 Methane
CML Centrum voor Milieukunde Leiden (Centre for Environmental Sciences, Netherlands)
CO Carbon monoxide
CO2 Carbon dioxide
DIN Deutsche Industrienorm (German Industrial Standard)
DPF Diesel particle filter
EDW Einwohnerdurchschnittswert (average impact per inhabitant)
EN European standard
EP Eutrophication potential
GJ Gigajoule
GWP Global warming potential
HC Hydrocarbons
KBA Kraftfahrtbundesamt (German Federal Motor Transport Authority)
kW Kilowatt
LCA Life Cycle Assessment
LCI Life Cycle Inventory
MISS Volkswagen Material Information System
MPI Intake-tube multipoint injection gasoline engine
N2O Nitrous oxide
NEDC New European Driving Cycle
NH3 Ammonia
Nm Newton metre
NMVOC Non-Methane Volatile Organic Compounds
NOX Nitrogen oxides
ODP Ozone depletion potential
PAN Peroxyacetylnitrate
PO4 Phosphate
POCP Photochemical ozone creation potential
ppm parts per million
PVC Polyvinyl chloride
R11 Trichlorofluoromethane (CCl3F)
SET Simultaneous engineering team
SF6 Sulphur hexafluoride
SO2 Sulphur dioxide
TDI Turbocharged direct injection diesel engine
TSI Turbo- or twincharged direct injection petrol engine
VDA Verband der deutschen Automobilindustrie (Association of the German
Automotive Industry)
VOC Volatile organic compounds

32
List of figures and tables

List of figures
Fig. 1: Powertrain and Fuel Strategy of the Volkswagen Group
Fig. 2: Environmental goals of the Technical Development department of the Volkswagen brand
Fig. 3: Input and output flows for a Life Cycle Inventory
Fig. 4: Procedure for Impact Assessment
Fig. 5: Dismantling study of the Golf V
Fig. 6: Process of modelling an entire vehicle with the VW slimLCI interface system
Fig. 7: Scope of the Life Cycle Assessment
Fig. 8: Material composition of transmissions compared
Fig. 9: Life Cycle Impacts (differential) of DSG gearboxes
Fig. 10: Life Cycle Impacts (differential) of DSG gearboxes (detail)

List of figures
Table 1: Technical data of transmissions compared
Table 2: Average impact per inhabitant figures in the EU 15, 2001
Table 3: Assumptions and definitions for the Life Cycle Assessment
Table 4: Selected Life Cycle Inventory values (in kg)

33
Appendix

Appendix
When this initial detailed version of the Environmental Commendation was printed, the
TÜV NORD report had not yet been released for publication. It will appear here as soon as
the final version is available.

34
© Volkswagen AG
Konzernforschung Umwelt Produkt
Brieffach 011/1774
38436 Wolfsburg

October 2008